Detailed Project Report on Continuous Sandwich Panel Line

CONTINUOUS SANDWICH PANEL LINE

[EIRI/EDPR/4343] J.C.: 2528XL

INTRODUCTION

A Sandwich Panel consists of a core/insulating material of low density sandwiched between two layers of metal, bonded under pressure. The sandwich panel market is expected to witness a high growth rate during the forecast period, 2018 to 2023. The major end-user industries of sandwich panel market include industrial buildings, commercial buildings, cold storage facilities, warehouses, amongst others. Sandwich panels provide a quite level of thermal, sound, water insulation, and also prevent moisture condensation. Sandwich panel is more economical than the conventional methods when assessed with the concept of cost-benefit analysis. Increasing awareness about the energy efficient buildings, improvement in thermal performance of sandwich panels and implementation of stringent energy conservation regulations are expected to be the major drivers for the growth of sandwich panel market during the forecast period.

Buildings & construction is one of the major end-user industries driving the growth of sandwich panel market. With rapid industrialization in the emerging economies, the need for less time-consuming construction solutions is growing which in turn increases the demand for sandwich panels. Due to their easy installation property, sandwich panels are cost-effective and inexpensive when compared to other wall assemblies. The average growth in the global construction spending has been recorded at 8.1% in the last five years. The non-residential construction spending has increased to 4.1% in 2016, and this trend is expected to continue in the coming years. Increasing adoption of the sandwich panels for residential, commercial, and infrastructure development is expected to boost the market in the coming years.

Sandwich Panel

Sandwich panels are made of two colors coated metal sheets with an insulation material sandwiched in between. Sandwich panel made of

PPGI

• Pre-painted Galvanizing Iron / Galvalume

• Total Coated Thickness: 0.35mm /0.4mm /0.45mm /.5mm PUF

• Short form of Polyurethane Foam.

• Composition of 2 chemical: - Polyol and Isocynate

• Density: - 40kg/cu.m +/- 2 kg/cu.m

Continuous sandwich panels are single piece, prefabricated, modular, factory made units which consist of an insulating layer of rigid polyurethane foam between two layers of metal sheets. The panels comprise of PUF bonded between two sheets of Pre-coated GI sheets of 0.5 mm thick to produce straight-to-finish panels. Insulation core provides effective insulation and strong bonding for better structural stability to facilitate higher loading and wider spans. These panels are available for both wall and roof. 

The system can incorporate all types of architectural features like coving, boxes, cantilevers, projections, infill walls, mezzanine floors etc. This system can also incorporate all types of services viz. electrical, gas and plumbing etc. The design and engineering of the structures is executed by following the norms & guidelines stipulated in relevant Indian Standards.

Typical Isometric views of both roof and wall panels are shown in Figs. 1 & 2 respectively

Fig. 1 Roof Panel

Fig. 2 Wall Panel

Size of Panels

Panels are available in thickness from 25mm to 150mm, width 1000mm and length as per requirement of the customer

Profiles of the Panels

(A) Coldwell Wall panels

Coldwell wall panels are tongue-n-groove joinery for air-tight, effective panel to panel interlocking which provides an effective seal. Two types of panels – single groove and double groove systems are manufactured. While single groove panels are suitable for general purpose and application in buildings and shelters; double groove panels are suitable for cold room and cold chamber applications. Double groove ensures precise interlocking, dimensional accuracy and also eliminates the risk of air gaps and thermal bridging. Coldwell panels are in higher thicknesses are self-supporting free standing upto 6 metres. All joints are covered with flashings.

Profiles of these panels are given below:

Inner & Outer skin: 3 types of rib configuration – Micro-rib, Wave and Mini box.

Facing Options: Pre-painted galvanized steel/aluminium, stainless steel and craft paper and perforated metal sheet for inner skin

Surface finish: Metallic, solid colours, Polyvinylidene fluoride (PVDF) & super polyester coatings.

Coldwell-1

These panels are available in thickness of 30, 40, 50, 60, 80 & 100mm. Detail of this panel is shown in Fig. 3.

Coldwell -2

These panels are available in thickness of 80, 100, 120 & 150mm. Detail of this panel is shown in Fig. 4.

(B) Strupan Roof panel

Strupan is a structural roof panel with a trapezoidal profile on the top surface and a ribbed liner tray on the underside and a sandwiched insulation cover.

Profile of this panel is given below:

Inner skin: Ribbed liner, aluminium foil/craft paper

Outer skin: 35x250mm trapezoidal profile with 2 secondary ribs and anti-capillary flute.

This panel is available in thickness of 30, 40, 50, 60, 80 & 100mm

Surface finish: Metallic, solid colours, Polyvinylidene fluoride (PVDF) & super polyester coatings. Detail of this panel is shown in Fig. 5.

(C) Isoclad

Isoclad panels act as partition walls as well as façade cladding with permanent finishing and can be integrated well with structural glazing, curtain walls, windows and other type of fenestrations and openings.

Profile o this panel is given below:

Skins: 3 types of rib configuration – Micro-rib, Wave and Mini box

This panel is available in thickness of 40, 50, 60 & 80mm.

Facing options: Pre-painted galvanized steel/aluminium

Surface finish: Metallic, solid colours, Polyvinylidene fluoride (PVDF) & super polyester coatings. Detail of this panel is shown in Fig. 6.

Polystyrene sandwich panels

Being a kind of new type of multi-functional building material, it consists of steel plate at both side and polystyrene sandwiched. They are bonded with high intention adhesive at high temperature and pressure through auto forming machine.

Light in deadweight: 10-14Kg/SQM, easy to install (don't need crane), short construction period and low cost.

Large load: Used as supporting structure and defense device for its characteristic of high intention rigidity.

Flexible to use: Controlled by computer in its continuous assembly line, the length of them can be chosen at your willing.

Heat and sound insulation: Average thermal conductivity not less than 0.04w/m. K.

Mineral wool sandwich panels

Mineral wool sandwiched panels is made of 2 layers weatherproof color-plating steel plates or other metal plates and mineral wool sandwiched which is the best fireproof materials. It is suitable for various roofs and walls referring to the large-size factory buildings, storages, exhibition halls, freezing stores, purifications workshops, etc, which features temp-keeping, heat insulation, weight-bearing, weatherproof with the rich colorfulness and good appearance.

COST ESTIMATION

Plant Capacity                                   2000 SQM/Day

Land & Building (2750 sq.mt.)  Rs. 2.70 Cr

Plant & Machinery                              Rs. 28.44 Cr

Working Capital for 1 Month            Rs. 2.68 Cr

Total Capital Investment                    Rs. 34.84 Cr

Rate of Return                                     33%

Break Even Point                                 55%

CONTENTS

INTRODUCTION

SANDWICH PANEL

PPGI

FIG. 1 ROOF PANEL

FIG. 2 WALL PANEL

SIZE OF PANELS

PROFILES OF THE PANELS

(A) COLDWELL WALL PANELS

PROFILES OF THESE PANELS ARE GIVEN BELOW:

COLDWELL-1

COLDWELL -2

(B) STRUPAN ROOF PANEL

PROFILE OF THIS PANEL IS GIVEN BELOW:

(C) ISOCLAD

PROFILE OF THIS PANEL IS GIVEN BELOW:

POLYSTYRENE SANDWICH PANELS

MINERAL WOOL SANDWICH PANELS

PU SANDWICH PANEL

PU SANDWICH PANEL FEATURES:

POLYURETHANE-SANDWICHED PANEL

1. PUF PANEL FORMULATION

2. SPECIFICATION OF PUF PANEL

PROPERTIES OF PUF

ADVANTAGES/DISADVANTAGES OF PUF PANEL

ADVANTAGES

DISADVANTAGES

USES/APPLICATIONS

APPLICATION (INDUSTRIES)

MARKET OVERVIEW

COMPETITIVE INDUSTRY

NOTABLE PLAYERS IN THE SANDWICH PANELS MARKET INCLUDE

REGIONAL INSIGHTS

GLOBAL SANDWICH PANELS MARKET INFORMATION

MAJOR MARKET DRIVERS

BIS SPECIFICATION

RAW MATERIALS

CONTINUOUS PRODUCTION PROCESS/PRODUCTION LINE

THERE ARE BASICALLY TWO PANEL MANUFACTURING TECHNOLOGIES:

CONTINUOUS PANEL PRODUCTION LINE

A TYPICAL CONTINUOUS LINE IS MADE UP OF THE FOLLOWING THREE SECTIONS:

MANUFACTURING PROCESS STEPS

PROCESS FLOW

TESTING

TESTING: FOR QUALITY CONTROL:

DIMENSIONAL TOLERANCE FOR SANDWICH PANELS

TRANSVERSE BOW – CUPPING OF THE PANELS

FOLLOWING TEST ARE CONDUCTED ON THE FINISHED PUF PANELS

PLANT & MACHINERY

UNCOILER

LOADING COIL CARS

ROLL FORMING UNIT

PRE-HEATING OVEN

PRE-HEATING OVEN

METERING MACHINE

REACTIVE MIXTURE DISTRIBUTION

FLEXIBLE FACE UNCOILERS

DOUBLE CONVEYOR BELT

PANELS CUTTING UNIT

THESE UNITS CAN BE EITHER:

PANELS UNLOADING AND STACKING LINE

SUPPLIERS OF CONTINUOUS SANDWICH PANEL

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PPGI SHEET

SUPPLIERS OF PUR/PIR MATERIAL

SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS

CONTINIOUS SANDWICH PANNEL PRODUCTION LINE

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

ELECTRICAL MEASURING INSTRUMENTS

DG SETS

EOT CRANES

POWER TRANSFORMERS

ELECTRICAL PANEL

ELECTRIC MOTOR

COOLING TOWER

EFFULENT TREATMENT PLANT (ETP PLANT)

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

SHOT BLASTING MACHINE

JIGS AND FIXTURE

SUBMERSIBLE WATER PUMP

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

SPECIFIC FACTORS

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

VULNERABILITY TO WARTIME ATTACK:

FLOOD AND FIRE CONTROL:

WASTE MANAGEMENT

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)